# US 9,040,656 B2 · Process for producing spherical particles of furfuryl alcohol resin, spherical particles of furfuryl alcohol resin produced by the process, spherical carbon particles and spherical activated carbon particles

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- Number: US 9,040,656 B2
- Document ID: US9040656B2
- Status: Granted
- Kind: B2
- Application number: 13/961,349
- Filed: 2013-08-07
- Published: 2013-11-28
- Granted: 2015-05-26
- Earliest claimed: 2011-03-17
- Assignees: Asahi Organic Chemicals Industry Co., Ltd.
- Applicants: Asahi Organic Chemicals Industry Co., LTD.
- Inventors: Yasuhiro Matsumoto; Yuta Murai
- Web page: https://patentgrep.com/patent/US9040656B2

## CPC

- C08F 134/02: in a ring containing oxygen
- C01B 32/05: Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
- C01B 32/336: characterised by gaseous activating agents
- C08G 65/36: Furfuryl alcohol
- C08L 71/14: Furfuryl alcohol polymers
- C08L 2205/18: Spheres
- Y10T 428/2982: Particulate matter [e.g., sphere, flake, etc.]
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Providing a process for advantageously producing spherical particles of furfuryl alcohol resin using only furfuryl alcohol without using a harmful aldehyde as a starting material. In the process, furfuryl alcohol is subjected to a self-condensation reaction in the presence of an acid catalyst, whereby a fluidic condensation resin of furfuryl alcohol is obtained. The condensation resin of furfuryl alcohol is granulated and cured using water as a reaction medium in the presence of a dispersion stabilizer and an acid catalyst having a pKa of not more than 1.5, whereby spherical cured resin particles are formed.

## Claims

### Claim 1

A process for producing spherical particles of furfuryl alcohol resin, comprising the steps of:
performing a self-condensation reaction to furfuryl alcohol in the presence of a first acid catalyst to provide a fluidic condensation resin of furfuryl alcohol; and
granulating and curing the condensation resin of furfuryl alchohol, using water as a reaction medium in the presence of a dispersion stabilizer and a second acid catalyst having a pKa of not more than 1.5, to provide the cured spherical particles of furfuryl alcohol resin.

### Claim 2 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the first acid catalyst used in the self-condensation reaction has a pKa of less than 8.

### Claim 3 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the first acid catalyst is used in an amount of 0.1-50% by mass with respect to an amount of the furfuryl alcohol.

### Claim 4 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the condensation resin of furfuryl alcohol has a weight-average molecular weight of 150-100000.

### Claim 5 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein an amount of the dispersion stabilizer is 0.01-100% by mass with respect to an amount of furfuryl alcohol used in the self-condensation reaction.

### Claim 6 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the dispersion stabilizer is a protective colloid or a surfactant.

### Claim 7 (depends on 6)

The process for producing spherical particles of furfuryl alcohol resin according to claim 6, wherein the protective is at least one of hydroxyethyl cellulose, partially hydrolyzed polyvinyl alcohol, and gum arabic.

### Claim 8 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein an amount of the second acid catalyst is 0.05-100% by mass with respect to the furfuryl alcohol used in the self-condensation reaction.

### Claim 9 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the second acid catalyst is benzenesulfonic acid.

### Claim 10 (depends on 9)

The process for producing spherical particles of furfuryl alcohol resin according to claim 9, wherein the benzenesulfonic acid is alkylbenzene sulfonic acid.

### Claim 11 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein the spherical particles of furfuryl alcohol resin has an average particle diameter of 1-1500 μm.

### Claim 12 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein a reaction medium of the self-condensation reaction is not more than 25 times by mass of water with respect to an amount of the furfuryl alcohol.

### Claim 13 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein an amount of water is used as the reaction medium for curing is 0.5-25 times by mass with respect to an amount of furfuryl alcohol used in the self-condensation reaction.

### Claim 14 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein a reaction temperature employed for curing is not lower than 50° C.

### Claim 15 (depends on 1)

The process for producing spherical particles of furfuryl alcohol resin according to claim 1, wherein a reaction temperature employed during the self-condensation reaction is not lower than 30° C.